Polycarbonate-polyvinyl chloride moulding compositions

ABSTRACT

Moulding compositions consisting of A. 5 - 95 PARTS BY WEIGHT OF A POLYCARBONATE, B. 5 - 95 PARTS BY WEIGHT OF A VINYL CHLORIDE POLYMER AND C. 5 - 95 PARTS BY WEIGHT OF AN ABS graft polymer, a styrene/maleic anhydride copolymer or an ethylene/vinyl acetate copolymer.

United States Patent Elghani et a1.

May 6, 1975 POLYCARBONATE-POLYVINYL CHLORIDE MOULDING COMPOSITIONS Inventors: Salah Elabd Elghani; Winiried Fischer, both of Cologne, Germany; Michael Koehler, Wien, Austria; Johannes Lindner, Hamburg; Richard Prinz, Levcrkusen, both of Germany Bayer Aktiengesellschait, Leverk usen, Germany Filed: Jan. 28, 1974 Appl. No.: 437,154

Assignec:

Foreign Application Priority Data Feb. 1, 1973 Germany .4 2304894 US. Cl. 260/873; 260/876; 260/899 Int. Cl. COSg 39/10 Field of Search 260/873 75 R, 92.8 R

[561 References Cited UNITED STATES PATENTS 3,130,177 4/1964 Grabowski 260/873 X 3,239,582 3/1966 Keskkula et :11. 4 260/873 3,305,605 2/1967 Hostettler et a1. 1 1 260/873 3,663,471 5/1972 Schirrner ct a1. 260/873 X Primary ExaminerMelvin Goldstcin Assistant Examiner-E. A. Nielsen Attorney, Agent, or FirmConno11y and Hutz 3 Claims, No Drawings 1 POLYCARIN )N ATE-POLYVINYL CHLORIDE MOULDING COMPOSITIONS This invention relates to thermoplastic moulding compositions of a. 5 95 parts by weight of a polycarbonate,

b. 5 95 parts by weight of a vinyl chloride polymer and c. 5 95 parts by weight of an ABS polymer or of a styrcnc/maleic anhydride copolymer or of an ethylene/vinyl acetate copolymcr,

Preferred moulding compositions contain 20 to 80 parts by weight of each of (a), (b) and (c).

Particularly preferred moulding compositions contam a. 30 50 parts by weight of polycarbonate,

b, 30 50 parts by weight of polyvinyl chloride and c. 30 50 parts by weight of ABS graft polymer.

Polycarbonates for the purpose of this invention are preferably polycarbonates based on divalent phenots, e.g. hydroquinone, resorcinol, 4,4 '-dihydroxydiphenyl, bis-(4-hydroxyphenyl)-alkanes, -cycloalkanes, -ethers, -sulphones or -ketones, bisphenols which are halogenated in the nucleus and a, a-bis-(p-hydroxyphenyl)- p.diisopropyl-benzene. The preferred phenols are 4,4- dihydroxydi-phenylpropane-(2,2) (bisphenol A), tetrachlorobisphenol A, tetrabromobisphenol A and trinuclear bisphenols such as a, 0: -bis-( 4- hydroxyphenyl)-p-diisopropylbenzene. The preparation of polycarbonates from these phenols is already known. Polycarbonates are basically prepared by react ing phenols with derivatives of carbonic acid such as phosgene or bischlorocarbonic acid esters. Particularly suitable polycarbonates have molecular weights of 10,000 to 100,000, preferably 20,000 to 60,000 (US. Patent Nos. 3,028,365; 2,999,835; 3,148,172; 3,271,368; 2,970,137; 2,991,273; 3,271,367;

3,280,078; 3,014,891 and 2,999,846).

Vinyl chloride polymers for the purpose of this invention are polyvinyl chloride and copolymers of vinyl chloride with olefinically unsaturated polymerisable compounds which contain at least 80 percent by weight of vinyl chloride incorporated by polymerisation. Olefinically unsaturated compounds which are suitable for copolymerisation are, for example, vinylidene halides such as vinylidene chloride and vinylidene fluoride, vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate, vinyl chloroacetate, vinyl benzoate, acrylic and a-alkyl-acrylic acids and their alkyl esters, amides and nitriles such as acrylic acid, methacrylic acid, methyl methacrylate, ethyl acrylate, 2-ethylhexyl acrylate, butyl methacrylate, acrylamide, N-methyl acrylamide, acrylonitrile and methacrylonitrile, aromatic vinyl compounds such as styrene and vinyl naphthalene and olefinically unsaturated hydrocarbons such as ethylene, bicyclo-[2,2,l l-hept-2'ene and bicyclo-[2,2,l hepta-2,5-dienes. These vinyl chloride polymers are known and can be prepared by the usual methods of emulsion, suspension, bulk or mass polymerisation. Vinyl chloride polymers which have molecular weights of 40,000 to 60,000 are preferred. The vinyl chloride polymers may contain the usual additives such as dyes, pigments, stabilisers, lubricants and plasticizers. Rechlorinated polyvinyl chloride or chlorinated polyethylene are also suitable (see DAS No. 1,098,716).

ABS graft polymers are in particular elasticthermoplastic products which are obtained by polymerising a 50 percent by weight of a monomer mixture of 95 50 parts by weight of styrene, styrene alkylated in the nucleus or side chain, methyl methacrylate or mixtures thereof and 5 50 parts by weight of acrylonitrile, alkyl acrylonitrile, methyl methacrylate or mixtures thereof, entirely or partly in the presence of 50 5 percent by weight ofa rubber. Mixtures of such graft copolymers with a copolymer of 95 50% by weight of styrene or styrene which is alkylated in the nucleus or side chain, methyl methacrylate or mixtures thereof and 5 50 percent by weight of acrylonitrile, alkyl acrylonitrile, methyl methacrylate or mixtures thereof are also suitable (see British Pat. No. 794,400).

Rubbers suitable as grafting bases are, for example diene rubbers such as homopolymers of butadiene and isoprene or copolymers of butadiene or isoprene with up to 20 percent by weight of styrene. Other suitable rubbers are ethylenepropylene terpolymers. These are polymers of ethylene, propylene and a non-conjugated diene in which the proportion by weight of ethylene units to propylene units is from 20 80 to 80 20 and which contain up to 15 percent by weight of the nonconjugated diene incorporated by polymerisation. Preferred non-conjugated dienes are norbornadiene, hexadiene-( 1,5) and ethylidene norbornene.

When preparing the ABS graft copolymers, 20 percent of the monomers present are generally graft to polymerised while the remainder are copolymerised separately and added.

Styrene/maleic anhydride copolymers which are used according to the invention may contain the two monomer components in practically any by weight ratio. The molecular weight may also vary within wide limits. The copolymers are generally prepared by reacting maleic anhydride and styrene at elevated temperatures in the presence of peroxide catalysts, Styrene may also be partly or completely replaced by its derivatives such as oz-methyl styrene, vinyl toluene, 2,4-dimethyl styrene or chlorostyrene. The copolymers of styrene and maleic acid anhydride generally have molecular weights of 2,000 to 300,000, preferably 80,000 to 200,000. The amount of maleic anhydride units is generally 5 50 percent by weight, preferably 5 30 percent by weight (see US. Pat. Nos. 2,866,771 and 2,971,939).

Suitable ethylene/vinyl acetate copolymers may contain l 80 percent by weight of vinyl acetate, preferably 3 50% by weight. The products may be prepared e.g. by high-pressure polymerisation or by polymerisation in emulsion or solution. Their molecular weights are generally between 10,000 and 500,000, preferably between 80,000 and 120,000 (see US. Pat. No. 3,325,460).

To prepare the moulding compositions according to the invention, solutions of the three polymer components in suitable inert organic solvents (e.g. chlorinated hydrocarbons such as methylene chloride, chloroform, chlorobenzene or phenols such as cresol or phenol) may be mixed together. The usual additives such as stabilisers, lubricants, dyes or effect substances may then be added to the mixtures. ABS graft polymers are usually not in true solution but in the form of fine dispersions, eg. colloidal dispersions. The moulding compositions can be isolated from the solutions by precipitation with non-solvents or by removal of the solvents by distillation.

The moulding compositions are preferably prepared by mixing the polymer components in the molten state.

For this purpose, the components may be melted together, mixed and extruded, e.g. in extruders fitted with mixing devices. Alternatively. the polymers may be melted separately and then extruded together. It is particularly preferred first to mix the vinyl chloride polyate additives. The mixture consists of 40 parts of polycarbonate, 20 parts of polyvinyl chloride and 40 parts of ABS graft polymer.

EXAMPLE 5 5 mer with the ABS graft polymer. h styr n lmalel The moulding composition is prepared as described hydride copolymer or ethylene/vinyl ac tat copolyin Example I, using the same polymers with the appromer by melting them together and then to add the polypriate additives. The mixture consists of 40 parts of carbonate optionally also in the molten state, to this polycarbonate 35 parts f polyvinyl Chloride and 25 molten mlxtufeparts of ABS graft polymer.

The mixtures according to the invention are thermoplastic moulding compositions which are suitable for EXAMPLE 6 injection moulding emulsion and g- The moulding composition is prepared as described lmpflct Strengihnotched p i Strength and heat in Example I, using the same polymers with the approtortion temperature are substantially greater than those 15 priate additives. The mixture consists of 40 parts of of polyvinyl chloride. Their ball indentation hardness, l b t 50 parts f polyvinyl chlorid d 10 tensile strength, flexural strength, flame resistance and n f ABS ft polymen elastic modulus are considerably better than the corresponding values of polycarbonate. EXAMPLE 7 EXAMPLE 1 2O 2O?)5Cpa1r tl s of lpolyvilnylflchlcgiride lzzrle plasticised at e po yviny c ori e, sta iised and mixed A pulverulem m'xture of 55 parts welght of ABS with lubricants, has the same composition as in Examgl'aft Polymer (from 15 Parts f Putadlene, 63 Parts of ple A mixture of 40 parts of a polycarbonate of 4,4- f and pans of l and 5 parts of dihydroxydiphenyl-propane-(2,2) having a relative visy! ch]0nde (PVC) plasnclsfid at 2 The cosity of L28 (determined on a solution of 0.5 g of the stabilised polyvinyl chloride to which lubricants have polycarbgnate in 00 ml of methylene Chloride) and 25 been added has fclllowmg composmon: parts of a copolymer of styrene and maleic anhydride pans of slfspenslon K' (molar ratio 88 [2) which has a relative viscosity of 4.5 parts of di-ri-octyl-tin dithioglycollic acid ester L49 (determined cm a Solution of 05 g of thg cope]? and 1 Pan of Loxlol G 33 (Henkel'l DFSSddOYf); met in 100 ml of methylene chloride) is melted in an 40 Parts Ofa polycarimnate 1 b f extruder at about 250C. This mixture of polycarbon- "Y -P PP havlng a relauve Vlscoslty 0f '2 ate and styrene/maleic anhydride copolymer is added (demrmmed a soluuon g of Polycarbonate m to a plasticised polyvinyl chloride and the components 100 ml of methylene chloride) are melted in an exare the mixed in a thermoplastic state truder at about 250C. The plasticised polycarbonate is 35 added to the ABS/PVC mixture and the components EXAMPLE 8 are mlxed i the hemoplasm State The moulding composition is prepared as described Some mechanical properties of the moulding compon r in Example 7, using the same polymers and appropriate sitions obtained in this and the following examples are y additives. The mixture consists of 30 parts of polycarsummarised in a table. The parts of the examples are in 40 bonate, 40 parts of polyvinyl chloride and 30 parts of all cases parts by weight.

styrene/maleic anhydride copolymer. EXAMPLE 2 EXAMPLE 9 The moulding composition is prepared in the same I way as described in Example 1, using the same poly- 5 A mlxture of 30 Paris of Polyvmy' chlonde 5 mers with the appropriate additives. The mixture con- Parts an ethylene/wily! copolymer which sists of 40 parts of polycarbonate. 10 parts of polyvinyl comams pefifem by weght of F E P has Chloride and parts of ABS graft pen/men a moleculgr weight of about lOK LOOO is plasticised at about 200 C. The polyvinyl chloride has the same com- EX MP 3 50 position as in Example l. The method employed is the The moulding compositiun is prepared as described same as described in Example 1 except that 65 parts of in Example 1 using the same polymers with appropriate polycarbonate am used" additives. The mixture consists of 40 parts of polycarbonate, 15 parts of polyvinyl chloride and 45 parts of EXAMPLE ABS graft polymer. The moulding composition is prepared as described in Example 9 and the same polymers are used with the EXAMPLE 4 appropriate additives. The mixture consists of 40 parts The moulding composition is prepared as described of polycarbonate, 57 parts of polyvinyl chloride and 3 in Example 1, using the same polymers with appropri- 60 parts of ethylene/vinyl acetate copolymer.

EXAMPLES Property Test Measuring Method unit I 2 3 4 5 6 7 8 9 it) lmpact DIN 53453 cmkp/cm ununununununununstrength RT broken broken broken broken broken broken 5'. 36 broken broken 77 4x 24 23 41 Notched DlN 53453 cnrkp/cm l4 l3 [(1 7.5 l5 7 L7 2 45 1.7 impact strength RT -4UC Zn 2.5 2.5 2.3 5 2 4.6 A ,6

Continued EXAMPLES Property Test Measuring Method unit I 2 3 4 5 6 7 8 9 I Tensile strength DIN 53455 kp/cm 580 575 570 570 630 600 620 640 (TS Elongation at US DIN 53455 Z 3.7 3.7 3.6 3.7 5.6 5.8 3.4 3.7 Modulus of I00 elasticity DIN 53455 kp/cm 240 250 250 245 265 270 297 280 Flexural strength DIN 53452 kp/cm 975 970 970 975 945 950 I085 I090 900 930 ahF Sagging DIN 53452 mm 4.6 4.6 4.6 4.3 5 4.7 4.9 49 Ball indententative tation hurdstandard kp/cm I I I130 l I30 I I20 I 145 I I50 I290 I270 950 I I45 ness H DIN 53456 Vicat dimensional DIN 53460 C I08 I03 I09 I09 I04 I02 I I0 I10 I I2 93 stability in the heat W6 Claim 29 sisting of diene polymers and ethylene-propylene- A moulding composition consisting essentially of a. 5 to 95 parts by weight of a polycarbonate of a dihydric phenol and a derivative of carbonic acid, b. 5 to 95 parts by weight of a vinyl chloride polymer containing at least 80 parts by weight of vinyl chloride and 5 to 95 parts by weight of a graft copolymer obtained by polymerizing a monomer mixture of styrene, an -alkyl styrene, methyl methacrylate, or a mixture thereof with acrulonitrile, an alkyl acrylonitrile, methyl methacrylate, or a mixture thereof, in the presence of a rubber selected from the group connon-conjugated diene terpolymers, a copolymer of styrene and maleic anhydride or a coploymer of ethylene and vinyl acetate containing l to 80 percent by weight of vinyl acetate.

2. The moulding composition of claim I consisting essentially of 20 to 80 parts by weight of each of (a),

(b) and (c).

3. The moulding composition of claim 1 consisting essentially of 30 to 50 parts by weight of each of (a), (b) and (c). 

1. A MOULDING COMPOSITION CONSISTING ESSENTIALLY OF A. 5 TO 95 PARTS BY WEIGHT OF A POLYCARBONATE OF A DIHYDRIC PHENOL AND A DERIVATIVE OF CARBONIC ACID, B. 5 TO 95 PARTS BY WEIGHT OF A VINYL CHLORIDE POLYMER CONTAINING AT LEAST 80 PARTS BY WEIGHT OF A GRAFT COPOLYMER OBTAIN 5 TO 95 PARTS BY WEIGHT OF A GRAFT COPOLYMER OBTAINED BY POLYMERIZING A MONOMER MIXTUREE OF STYRENE, AN ALKYL STYRENE, METHYL METHACRYLATE, OR A MIXTURE THEREOF WITH ACRULONITRILE, AN ALKYL ACRYLONITRILE, METHYL METHACRYLATE OR A MIXTURE THEREOF IN THE PRESENCE OF A RUBBER SELECTED FROM THE GROUP CONSISTING OF DIENE POLYMERS AND ETHYLENE-PROPYLENE-NON-CONJUGATED DIENE TERPOLYMERS, A COPOLYMER OF STYRENE AND MALEIC ANHYDRIDE OR A COPOLYMER OF ETHYLENE AND VINYL ACETATE CONTAINING 1 TO 80 PERCENT BY WEIGHT OF VINYL ACETATE.
 2. The moulding composition of claim 1 consisting essentially of 20 to 80 parts by weight of each of (a), (b) and (c).
 3. The moulding composition of claim 1 consisting essentially of 30 to 50 parts by weight of each of (a), (b) and (c). 